Air ionization systems and methods

ABSTRACT

Ionization systems configured with a catalyst-bearing sleeve provide improved filtration while keeping ozone levels within acceptable limits. Modular configurations provide for serviceability and replaceability. System controls monitor particulates, temperature, humidity, and other relevant factors and adjust an ionization level accordingly for optimal performance.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/156,755, filed May 17, 2016, entitled “AIR IONIZATION SYSTEMS ANDMETHODS,” which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates to air purification, and in particular toremoval of particulates via ionization.

SUMMARY OF THE INVENTION

Disclosed is an air ionization unit that includes an ozone dampeningcatalyst surrounding the air ionization tube. The ozone dampeningcatalyst removes much or all of the ozone created by ionizing moleculesin the air. In one embodiment, rather than the air passing by theionization tube and being ionized in a known manner, air is drawn intoan ionization module through a filter that may be contained in themodule. The filtered air is then expelled, preferably by a fan, outwardinto a space between the ionization tube and the ozone dampeningcatalyst. The air is ionized in a standard manner, and ozone ispartially or totally removed by the ozone absorption tube.

The air ionization unit may be an integral, one-piece unit, so it can beremoved and replaced without having to disassemble it. In a preferredembodiment, the air ionization unit has a support plate that mountsdirectly or indirectly to the outside surface of an air passageway ductor other space (collectively, “duct”) that includes air to be cleaned.The air ionization tube and ozone dampening catalyst preferably extendoutward from the support plate and into the air duct. Fasteners on theoutside of the air duct can be removed to remove and/or replace theentire air ionization unit.

The invention may also include a controller that (1) measures the amountof particulate in the air, (2) measures the amount of negative and/orpositive ions in the air, (3) measures the amount of ozone in the air,(4) measures the amount of carbon monoxide in the air, (5) measures theair temperature and humidity, and/or (6) adjusts the amount of ionsbeing released into the air based on one or more measured parameters.

The contents of this summary section are provided only as a simplifiedintroduction to the disclosure, and are not intended to be used to limitthe scope of the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

With reference to the following description, appended claims, andaccompanying drawings as attached:

FIG. 1 is an exploded view of an air ionization unit in accordance withembodiments of the invention.

FIG. 2 is an assembled, perspective side view of the air ionization unitof FIG. 1.

FIG. 3 is an assembled side view of the air ionization unit of FIG. 1.

FIG. 4 is a cross-sectional, side view of the air ionization unit ofFIG. 3 taken along lines A-A.

FIG. 5 is an end view of the air ionization unit of FIG. 3.

FIG. 6 is the opposite end view of the air ionization unit of FIG. 3.

FIG. 7 is an exploded view of an ozone dampening module according toaspects of the invention.

FIG. 8 is a perspective, side view of the assembled ozone dampeningmodule of FIG. 7.

FIG. 9 is an exploded view of an ionization module according to aspectsof the invention.

FIG. 10 is an assembled, perspective side view of the ionization moduleof FIG. 9.

FIG. 11 is an assembled, side view of the ionization module of FIG. 9.

FIG. 12 is a cross-sectional, side view of the ionization module of FIG.11 taken along lines A-A.

FIG. 13 is a rear, perspective view of a control unit according toaspects of the invention.

FIG. 14 is a front, perspective view of the control unit of FIG. 13.

FIG. 15 is a front view of the control unit of FIG. 13.

FIG. 16 is a side view of the control unit of FIG. 13.

FIG. 17 is a rear view of the control unit of FIG. 13.

FIG. 18 is a perspective, side view of an ionization system inaccordance with aspects of the invention with the housing opened.

FIG. 19 is a perspective, side view of the ionization system accordingto FIG. 18 with the control unit and energy converter removed.

FIG. 20 is a partial exploded view of the ionization system of FIG. 18showing the ionization module removed from the housing, and the housingremoved from a support plate.

FIG. 21 shows a front, perspective view of an ionization systemaccording to the invention.

FIG. 22 shows a display that may be used in accordance with aspects ofthe invention.

FIG. 23 shows a sensor that may be used in accordance with aspects ofthe invention.

DETAILED DESCRIPTION

The following description is of various exemplary embodiments only, andis not intended to limit the scope, applicability or configuration ofthe present disclosure in any way. Rather, the following description isintended to provide a convenient illustration for implementing variousembodiments including the best mode. As will become apparent, variouschanges may be made in the function and arrangement of the elementsdescribed in these embodiments without departing from the scope of theappended claims.

For the sake of brevity, conventional techniques for ionization, airfiltration, ozone removal, and/or the like may not be described indetail herein. Furthermore, the connecting lines shown in variousfigures contained herein are intended to represent exemplary functionalrelationships and/or physical couplings between various elements. Itshould be noted that many alternative or additional functionalrelationships or physical connections may be present in a practicalionization system or related methods.

Prior approaches to air filtration and/or ionization suffer from variousdrawbacks. For example, certain air ionization systems, in order toavoid releasing an unacceptable level of ozone, generate ionizationlevels that are insufficient to fully clean and/or sanitize a particularair stream. Moreover, other air ionization systems have suffered from alack of configurability and/or intelligent control. Yet other airionization systems have been complex, expensive, and/or lacking inmodular configuration and/or serviceability. These and other drawbacksof prior approaches may remedied by principles of the presentdisclosure.

Turning now to FIGS. 1 through 6, a module 100 for ionizing air isshown. Module 100 as shown preferably has an end cap or “base” 102, anadapter 104, a coupler 106, an ion dispenser 108, a tube 110, an outerelectrode 112, and an inner electrode 114. Base 102 is preferablycomprised of any suitable plastic, for example injection-molded ABS (butnot ABS-PC) although any suitable material may be used. The purpose ofbase 102 is to receive coupler 106, ion dispenser 108, and tube 110.

Coupler 106 has a first end 105, a second end 107, an outer surface106A, and a passageway 106B extending therethrough. In some embodiments,coupler 106 comprises a hollow aluminum rod. Moreover, coupler 106 maycomprise a solid bar with an internal thread on each end. Coupler 106may be configured to conduct electricity.

Adapter 104 as shown is a threaded shaft that bases through an opening(not shown in these Figures) of second end 118 of base 102 and isthreadingly received in a passageway 106B at the first end 105 ofcoupler 106. The opening in second end 118 may also be threaded so as tothreadingly receive adapter 104. In the preferred embodiment shown,adapter 104 is a threaded shaft with a first end 104A and a second end104B. A nut 104C is threadingly received on the threaded shaft, end 105of coupler 106 is aligned with the opening on the inside of second end118. First end 104A passes through the opening and is threadinglyreceived in passageway 106B of coupler 106 to retain coupler 106 againstsecond end 118. In some exemplary embodiments, adapter 104 may comprisea solid stainless steel adapter with threaded ends and a centralintegral hex feature to facilitate rotation thereof.

An ion dispenser (also called an “umbrella shaped conductor”) 108 isattached to second end 107 of coupler 106. In various exemplaryembodiments, ion dispenser 108 may be configured with an umbrella-likeshape. However, ion dispenser 108 may be configured with any suitableshape, as desired. Ion dispenser 108 operates to dispense electricityinto inner electrode 114. Ion dispenser 108 as shown in this preferredembodiment is comprised of stainless steel (for example, stainless steelhaving a thickness of between about 0.006 inches and about 0.015inches), has a top 108A for attachment to coupler 106, and a pluralityof downward extending fingers 108B. In this preferred embodiment, iondispenser 108 is attached to coupler 106 by aligning an opening in top108A with passageway 106B at end 107 of coupler 106. Then fastener 113,which as shown is a bolt, is passed through opening 108C and threadedinto passageway 106B. A lock washer 113A may be positioned between top108A and the head of fastener 113.

Inner electrode 114 typically comprises a rolled perforated aluminumsheet, but may comprise any suitable material or combination ofmaterials configured to act as a first electrode for purposes ofionization.

Outer electrode 112 typically comprises a tubular stainless steel wiremesh, for example a 0.008 in diameter Type 316 stainless steel wire meshconfigured with a 20×20 per square inch grid. However, outer electrode112 may comprise any suitable material or combination of materialsconfigured to act as a second electrode for purposes of ionization.

A tube 110 is preferably glass (for example, comprised of borosilicate)and retains coupler 106 and ion dispenser 108. Tube 110 is alsooperative to insulate inner electrode 114 from outer electrode 112 andthus permit the development of a voltage potential therebetween in orderto facilitate ionization. Tube 110 has a first, open end 110A, an outersurface 110B, and a second end 110C. Preferably, after cap 102, coupler106, and ion dispenser 108 are assembled, inner electrode 114 is placedwithin tube 110, the first end 110A of tube 110 is positioned over iondispenser 108 and coupler 106, and is received in cap 102 in a snug toslightly loose fit. Outer electrode 112, which has a first end 112A, anouter surface 112B, a second end 112C, and an inner passage 112D, ispositioned over tube 110. In the preferred embodiment shown, outerelectrode 112 does not cover second end 110C of tube 110 or extend tocap 102.

In the preferred embodiment, when module 100 is assembled, coupler 106and ion dispenser 108 are positioned approximately 50-60% inside thelength of tube 110. In this manner, electrical current is delivered toapproximately the center of inner electrode 114.

With reference now to FIGS. 7 and 8, an ozone removal assembly 400comprises a tubular inner wall 406, a tubular outer wall 410, and a pairof ends 404. Inner wall 406, outer wall 410, and ends 404 may be coupledtogether to form a container for a catalyst media 408. In an exemplaryembodiment, inner wall 406 and outer wall 410 are coupled to a first end404 (for example, via RTV silicone). First end 404 is disposed on asurface, and the space between inner wall 406 and outer wall 410 isfilled with catalyst media 408. Second end 404 is then coupled to innerwall 406 and outer wall 410, securing catalyst media 408 in theresulting assembly. Inner wall 406 and outer wall 410 are configured tobe at least partially permeable to air. For example, inner wall 406 andouter wall 410 may comprise rolled stainless steel mesh screen or thelike.

In various exemplary embodiments, catalyst media 408 is configured toconvert, neutralize, and/or otherwise remove and/or reduce anundesirable compound in the air, for example ozone. Catalyst media 408may also be referred to as a “catalyst bed”, “reaction bed”, “ozonedestruction catalyst”, and/or the like. Catalyst media 408 may begranulated or otherwise shaped or formed to form part of ozone removalassembly 400. Catalyst media 408 typically comprises manganese dioxide,copper oxide, and/or the like, or combinations of the same. In someembodiments, catalyst media 408 comprises Carulite 200 offered by CamsCorporation (Peru, Ill.). However, any suitable catalyst configured toneutralize and/or remove ozone from an airstream may be utilized.

FIGS. 9 through 12 show an ionization and filter cartridge 200 accordingto a preferred embodiment of the invention. Cartridge 200 includespreviously described module 100. It also generally includes a housingand support structure, a fan assembly (or fan) 300, an ozone removalassembly 400, and an air filter 450. Air filter 450 may comprisepolypropylene, natural fibers, and/or the like. Air filter 450 isoperative to reduce the amount of dust and other airborne particulatesentering ozone removal assembly 400, as accumulation of dust on catalystmedia 408 reduces its efficacy.

The support structure of cartridge 200 includes a section for supportingmodule 100 and ozone removal assembly 400, and a section for supportingfan assembly 300, wherein, in the preferred embodiment, when cartridge200 is fully assembled, it is a single unit that may be removed andreplaced when desired.

Turning now to FIGS. 13 through 23, an exemplary ionization andfiltration system 600 utilizes module 100 and cartridge 200. System 600further comprises electronic controls 500. In various exemplaryembodiments, electronic controls 500 are configured to control module100 to generate an ionization level in excess of 66% negative ions; anegative ionization level significantly higher than previous systems. Inthis manner, module 100 generates a net excess of negative ions, andthus improved air filtration and clearing is achieved. In contrast,prior ionization systems typically generated approximately 50% positiveions and 50% negative ions, thus achieving limited efficacy as many ionsquickly recombined and/or neutralized one another and were thus nolonger available for air filtration and clearing. In some exemplaryembodiments, electronic controls 500 pulse power convertors 520 in amanner suitable to positively bias power convertors 520 with respect tocircuit ground; this results in generation of excess negative ions inmodule 100.

Additionally, electronic controls 500 may further comprise and/orcommunicate with various inputs (e.g., sensors) which monitor ionizationlevels, the density of particulates in the air, the ambient humidity,temperature, and/or the like. Based at least in part on the sensorinputs, electronic controls 500 adjust the operation of system 600 toachieve a desired level of filtration, ionization level, and/or thelike.

With reference now to FIGS. 13 through 17, electronic controls 500typically comprise various electronic components, for example: a printedcircuit board; RF module 510 for wireless communication via a suitablewireless protocol or protocols (for example, IEEE 802.11 (“WiFi”), IEEE802.15.4 (“ZigBee”), Bluetooth, GSM, and/or the like); powerconvertor(s) 520 for creating, modulating, transforming, and/orconverting AC and/or DC current, for example for use in operating module100 to produce ions; wired communication and/or input programmingport(s) 530; together with various resistors, capacitors, inductors,transistors, diodes, light-emitting diodes, switches, traces, jumpers,fuses, amplifiers, antennas, and so forth as are known in the art. Invarious exemplary embodiments, electronic controls 500 further comprisea microprocessor and/or microcontroller (for example, an 8-bit or 16-bitmicrocontroller, such as the PIC16F1503T-I/SL microcontroller offered byMicroChip Corporation of Chandler, Ariz.). The microcontroller isoperative for algorithmic (i.e., pre-programmed) operation, as well asresponsive (i.e., pursuant to sensor inputs, communications, etc)operation of system 600.

In one operating mode, electronic controls 500 are configured to operatemodule 100 at an 80% duty cycle (for example, 4 minutes in an iongeneration mode, followed by one minute powered down, followed by 4minutes in an ion generation mode, and so forth). In another operatingmode, electronic controls 500 are configured to operate module 100 at a100% duty cycle (always on). However, any suitable duty cycle may beutilized.

In various exemplary embodiments, electronic controls 500 are configuredto generate up to 6000 volts at frequencies between 1 kHz and 2 kHz foruse in ionization. Electronic controls 500 typically draw between about700 milliamps and about 900 milliamps. Power supplied to module 100 viaelectronic controls 500 may be digitally managed, for example via apulse width modulation (PWM) technique utilizing a fixed voltage andvariable duty cycle. Moreover, operating parameters for electroniccontrols 500 may be remotely managed.

In various exemplary embodiments, electronic controls 500 employ a“white noise” mode wherein power convertors 520 are turned on and/or offvia randomized timing. In this manner, transformer “whine” or “powerline hum” may be reduced and/or eliminated, making the resulting systemquieter and/or more suitable for indoor use.

In yet another operating mode, electronic controls 500 are configured tooperate system 600 in an “ozone depletion mode” whereby module 100 ispowered down and does not create ionization, but air is still passedthrough catalyst media 408, for example responsive to operation of fanassembly 100 (and/or as a result of ambient airstream movement, forexample in an HVAC duct). In this manner, system 600 is operative toremove ozone from the ambient air.

In various exemplary embodiments, electronic controls 500 monitor theperformance of module 100 and/or ozone removal assembly 400, and maysignal when a component of system 600 needs replacing (for example, dueto deterioration of ionization components in module 100, due to dustaccumulation on catalyst media 408 in module 400, and/or the like).

Electronic controls 500 are configured to monitor and control variousoperational characteristics of system 600, for example for safety. Invarious embodiments, electronic controls 500 monitor fan 300 speed andcurrent draw, as well as module 100 voltage and current draw. System 600may be shut down and/or restarted if an anomaly is detected.Additionally, electronic controls 500 may monitor status and errorconditions, turn an ozone depletion mode on or off, monitor temperaturelimits for operation, and/or adjust a duty cycle associated withoperation of module 100.

With reference now to FIGS. 18 through 21, system 600 may be configuredto be installed in a ventilation duct, for example an existing HVAC ductof a building. System 600 may be installed in connection with a newbuild, or as a retrofit.

While various exemplary embodiments of system 600 may be discussed inthe context of a residential HVAC installation, it will be appreciatedthat embodiments of the invention may be deployed in a wide variety ofform factors, installation locations, and uses. For example, system 600may be configured as: a desktop unit for placing on an office desk; afreestanding unit (for example, similar in form factor to a tower-stylefan); a unit for installation in a vehicle such as an automobile, bus,or airplane; or a high-volume unit for use in connection with ahospital, school, food processing plant, restaurant, and/or the like. Inparticular, system 600 may desirably be utilized to sanitize anddeodorize air that is exposed to or contains strong-smelling organiccontaminants, reducing and/or eliminating undesirable odors.

In some embodiments, with reference to FIG. 22 system 600 may furthercomprise a control panel 700. Control panel 700 comprises a display andvarious inputs, buttons, and the like. Control panel 700 is in wiredand/or wireless communication with control electronics 500. Via controlpanel 700, a user may view statistics regarding operation of system 600,give commands to system 600, view error messages or other system 600communications, and the like.

In various embodiments, with reference to FIG. 23 system 600 may furthercomprise one or more remote sensors 800. Remote sensor 800 is in wiredand/or wireless communication with control electronics 500. Remotesensor 800 comprises various sensors, for example a temperature sensor,particulate sensor, ozone sensor, carbon monoxide sensor, humiditysensor, and/or the like. Responsive to information received from remotesensor 800, control electronics 500 may modify operation of system 600,for example turning module 100 on or off, turning fan 300 on or off,and/or the like. For example, when remote sensor 800 reports ambientozone above a target threshold, control electronics 500 may operatesystem 600 in an ozone depletion mode for a period of time until ambientozone is below a target threshold. Likewise, when remote sensor 800reports that particulates are above a target threshold, controlelectronics 500 may increase the duty cycle of module 100 in order togenerate increased ionization and thus increase the rate of particulateremoval. Remote sensor 800 may be battery powered, or may be configuredto be plugged into a power outlet. Multiple sensors 800 may be utilizedto provide information regarding an operational environment to controlelectronics 500.

In various exemplary embodiments, operating parameters for system 600may be monitored and changed remotely, for example via wirelesscommunication. Changes for system 600 may be supplied via a connectedsoftware application operable on a tablet or smartphone, via controlpanel 700, via a universal serial bus connection to control electronics500, and/or the like.

While the principles of this disclosure have been shown in variousembodiments, many modifications of structure, arrangements, proportions,the elements, materials and components, used in practice, which areparticularly adapted for a specific environment and operatingrequirements may be used without departing from the principles and scopeof this disclosure. These and other changes or modifications areintended to be included within the scope of the present disclosure andmay be expressed in the following claims.

In the foregoing specification, the invention has been described withreference to various embodiments. However, one of ordinary skill in theart appreciates that various modifications and changes can be madewithout departing from the scope of the present invention as set forthin the claims below. Accordingly, the specification is to be regarded inan illustrative rather than a restrictive sense, and all suchmodifications are intended to be included within the scope of thepresent invention. Likewise, benefits, other advantages, and solutionsto problems have been described above with regard to variousembodiments. However, benefits, advantages, solutions to problems, andany element(s) that may cause any benefit, advantage, or solution tooccur or become more pronounced are not to be construed as a critical,required, or essential feature or element of any or all the claims.

As used herein, the terms “comprises,” “comprising,” or any othervariation thereof, are intended to cover a non-exclusive inclusion, suchthat a process, method, article, or apparatus that comprises a list ofelements does not include only those elements but may include otherelements not expressly listed or inherent to such process, method,article, or apparatus. Also, as used herein, the terms “coupled,”“coupling,” or any other variation thereof, are intended to cover aphysical connection, an electrical connection, a magnetic connection, anoptical connection, a communicative connection, a functional connection,and/or any other connection. When language similar to “at least one ofA, B, or C” or “at least one of A, B, and C” is used in the claims, thephrase is intended to mean any of the following: (1) at least one of A;(2) at least one of B; (3) at least one of C; (4) at least one of A andat least one of B; (5) at least one of B and at least one of C; (6) atleast one of A and at least one of C; or (7) at least one of A, at leastone of B, and at least one of C. The word “exemplary” is used herein tomean “serving as an example, instance or illustration”. Any embodimentdescribed as “exemplary” is not necessarily to be construed as preferredor advantageous over other embodiments and/or to exclude theincorporation of features from other embodiments.

What is claimed is:
 1. A method of removing contaminants from air, themethod comprising the steps of: (a) activating an ion generator togenerate more negative ions than positive ions; (b) operating a fan tomove air past the ion generator so the air acquires negative ions; and(c) passing the air with acquired negative ions through an ozone removalcatalyst at least partially surrounding the ion generator to removeozone from the air.
 2. The method of claim 1, wherein the ion generatorhas a duty cycle of 80%.
 3. The method of claim 1, wherein the ionsgenerated by the ion generator are at least 66% negative ions.
 4. Themethod of claim 1, further comprising the steps of: (a) receiving, at acontrol system of the ionization system, a sensor value indicating thatan ozone level in the air is above a threshold level; (b) disabling theion generator while keeping the fan operative to force air through theozone removal catalyst; and (c) re-enabling the ion generator responsiveto a sensor value indicating that an ozone level in the air is below thethreshold level.
 5. The method of claim 1, wherein the ozone removalcatalyst is part of an ozone removal assembly, wherein the assemblycomprises: (a) an inner stainless steel mesh screen forming a firsttube; (b) an outer stainless steel mesh screen forming a second tube;(c) a pair of end caps coupling the first tube and the second tube; and(d) the ozone removal catalyst being disposed between the first tube andthe second tube.
 6. The method of claim 1, wherein activating the iongenerator comprises positively biasing the output of a transformersupplying electrical current to the ion generator.
 7. The method ofclaim 1, further comprising the step of replacing the ion generator andthe ozone removal catalyst after a predetermined period of time.
 8. Themethod of claim 1 that further includes the step of a control systemenergizing the ion generator based at least in part on one or more ofthe measured ozone level in the air, air temperature, carbon monoxidelevel in the air, and the humidity level in the air.
 9. The method ofclaim 1, wherein the ion generator is cylindrical.
 10. The method ofclaim 1, wherein there is a space between the ion generator and theozone removal assembly.
 11. The method of claim 10, wherein the space iscylindrical.
 12. The method of claim 1, wherein the ion generator andozone removal catalyst are part of a modular unit that can be removedand replaced from an HVAC duct.
 13. The method of claim 12, wherein themodular unit further includes a fan.
 14. The method of claim 1, whereinthe ozone removal catalyst is granular.
 15. The method of claim 1,wherein the ozone removal catalyst comprises one or more of manganesedioxide and copper oxide.
 16. The method of claim 2 that furtherincludes a control system that automatically controls the ion generator.17. The method of claim 16, wherein the control system measures anamount of particulate in the air and energizes the ion generator basedat least in part on the measured amount of particulate in the air. 18.The method of claim 1, wherein the ion generator comprises: (a) astainless steel ion dispenser configured to receive electrical currentresponsive to operation of the control system, (b) an inner electrodeelectrically coupled to the ion dispenser, the inner electrodecomprising a perforated aluminum sheet, (c) a glass tube disposed atleast partially around the inner electrode, and (d) an outer electrodedisposed at least partially around the glass tube, the outer electrodecomprising a tubular stainless steel mesh screen.
 19. The method ofclaim 1, wherein the ion generator is disposed at least partially withinan HVAC duct.